Carrier with localized fibrous insert and methods

ABSTRACT

A structural reinforcement for an article including a carrier that includes: (i) a mass of polymeric material having an outer surface; and (is) at least one consolidated fibrous insert having an outer surface and including at least one elongated fiber arrangement having a plurality of ordered fibers arranged in a predetermined manner. The fibrous insert is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert and the mass of polymeric material are of compatible materials, structures or both, for allowing the fibrous insert to be at least partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier will be a mass of activatable material.

TECHNICAL FIELD

The present invention relates generally to structural reinforcement,sealing and/or baffling of an article, and more particularly tostructural reinforcement of an automotive vehicle by the use of improvedreinforcements adhered within a cavity of a transportation vehicle, suchas an automotive vehicle.

BACKGROUND

There is an ongoing effort in many industries to lighten the weight ofarticles. In many instances, this is achieved by the selection ofmaterials that have a lower density, thinner section thicknesses orboth, as compared with prior materials or structures. As a result, thereis a potential for the weakening of articles, and the consequent needfor structural reinforcement.

In the field of automotive vehicle manufacturing it is common to employstructural reinforcements within cavities of the vehicle body structure.For instance, it has become common to employ within a cavity of thevehicle body structure a relatively rigid molded polymeric carrier thatcarries an activatable material on one or more of its outer surfaces.For certain activatable materials, upon being activated (e.g., by theheat from a coating bake oven), the activatable material can expand andbond to a surface defining the cavity.

In order to selectively control the properties of the articlereinforcement structure, it has been taught to use hybrid reinforcementstructures that include a combination of multiple materials for thecarrier. See, e.g., U.S. Pat. No. 8,430,448, hereby expresslyincorporated by reference for all purposes. See also, Patent CooperationTreaty (PCT) Application No. WO 2010/054194, hereby expresslyincorporated by reference for all purposes.

In the automotive vehicle industry, the use of computer modeling (e.g.,finite element analysis) has been employed for simulating a vehiclecrash, and for modeling how a particular section of a vehicle willrespond to the crash.

Notwithstanding the above efforts there remains a need for alternativecarrier structures. For example, there remains a need for alternativecarrier structures that employ a combination of different materialsthat, even though they are dissimilar, are still generally compatible(e.g., chemically and/or physically compatible) with each other so thatthey can be joined together without the need for an adhesive. There alsoremains an ongoing need for alternative carrier structures that employ acombination of different materials that each contains a substantialpolymeric portion (e.g., a non-metallic portion) so that weight savingscan be attained. There also remains an ongoing need for alternativecarrier structures that employ a combination of different materials thatjoin together at an interface region that is generally continuous withthe portions of the carrier defined by the different respectivematerials. There also remains an ongoing need for an alternative carrierthat can employ one or more localized reinforcement regions by use of aparticular material within the carrier, and which may be achieved in theabsence of a need for a structural feature (e.g., a rib) for impartingthe localized reinforcement.

Examples of composite structures are illustrated in PCT Application No.WO 2007/008569, United States Published Patent Application Nos.2011/0039470 and 2012/0251863, and U.S. Pat. No. 7,581,932 allincorporated by reference for all purposes. See also, U.S. Pat. Nos.6,855,652 and 7,318,873, and United States Published Patent ApplicationNos. 2003/0039792, 2010/0289242, 2011/0278802, and 2009/0202294,incorporated by reference for all purposes.

The present application claims the benefit of the priority of GreatBritain Patent Application No. 1318595.4, filed Oct. 21, 2013, and U.S.Provisional Application No. 61/916,884 filed Dec. 17, 2013, the contentsof these applications being hereby incorporated by reference herein forall purposes.

SUMMARY OF THE INVENTION

One or more of the above needs are met by the present teachings whichcontemplate improved structures and methods that can be employedadvantageously for sealing, baffling and/or structurally reinforcingvarious articles, and particularly for structurally reinforcingtransportation vehicles, such as automotive vehicles.

In one aspect, the teachings contemplate a structural reinforcement foran article, including a carrier that includes: (i) a mass of polymericmaterial having an outer surface (e.g., an outer surface that isgenerally smooth and/or continuous); and (ii) at least one consolidatedfibrous insert (which may have a three dimensional shaped configuration)having an outer surface and including at least one elongated fiberarrangement having a plurality of ordered fibers (e.g., having a mass ofcontinuous fibers, which may be axially aligned), which may be arrangedin a predetermined manner. The fibrous insert is envisioned to adjointhe mass of the polymeric material in a predetermined location forcarrying a predetermined load that is subjected upon the predeterminedlocation (thereby effectively providing localized reinforcement to thatpredetermined location). The fibrous insert and the mass of polymericmaterial are of compatible materials, structures or both, for allowingthe fibrous insert to be at least partially joined to the mass of thepolymeric material. Disposed upon at least a portion of the carrier willbe a mass of activatable material (e.g., an expandable material). Forinstance, the mass of activatable material may be selectively appliedover at least a portion of one or both of the outer surface of the massof the polymeric material or the fibrous insert. The mass of activatablematerial may be capable of activation for expansion by an externalstimulus (e.g., to at least partially fill a gap or cavity) and also maybe capable of curing to form an adhesive bond to at least one surface ofthe article. Desirably, the outer surface of the fibrous insert is atleast partially co-extensive and continuous with the outer surface ofthe mass of polymeric material.

In another aspect, the teachings contemplate a method for making astructural reinforcement for an article. The method can include a stepof inserting at least one fibrous insert (which may be consolidatedand/or may have a predetermined three dimensional shaped configuration)having an outer surface and including at least one elongated fiberarrangement (e.g., having a mass of continuous fibers, which may beaxially aligned) into a cavity of a tool. A step may be employed ofmolding a mass of polymeric material in contact with the fibrous insertso that a resulting molded mass of polymeric material integrally adjoinsthe fibrous insert and the outer surface of the fibrous insert (whichmay be generally smooth and/or continuous) is at least partiallyco-extensive and continuous with the outer surface of the resultingmolded mass of polymeric material. Another step may be employed ofapplying a mass of activatable material selectively over at least aportion of one or both of the outer surface of the resulting mass of thepolymeric material or the fibrous insert. The mass of activatablematerial may be capable of activation for expansion by an externalstimulus to at least partially fill a gap or cavity and may be capableof curing to form an adhesive bond to at least one surface of thearticle.

In another aspect, the teachings herein contemplate a device comprisinga fibrous insert for forming a fiber reinforced thermoplastic sheet(e.g., a formed continuous fiber reinforced thermoplastic sheet, orfibrous insert), whereby the thermoplastic sheet is bonded to a mass ofpolymeric material (e.g. an additional strengthening material) and thedevice further includes an activatable material (which may be a heatactivated and/or foamable material). The activatable material may be afoamable and/or adhesive material. The mass of polymeric material mayprovide reinforcing ribs extending from one or both sides of the fiberreinforced thermoplastic sheet. The mass of polymeric material maycomprise short fiber (e.g. less than about 10 mm, or even less thanabout 5 mm in length) filled polyamide. The activatable material may beprovided on selected surfaces of the fiber reinforced thermoplasticsheet and/or the mass of polymeric material. The activatable materialmay be a heat activated thermosetting resin. The heat activatedthermosetting resin may be an epoxy resin.

The teachings herein further envision a process for the manufacture of adevice comprising thermoforming a fiber reinforced thermoplastic sheet,providing a mass of polymeric material to the thermoformed sheet andfurther providing an activatable material to the surface of thethermoformed thermoplastic sheet and/or the mass of polymeric material.The mass of polymeric material may be provided by placing thethermoformed sheet in a mold and injecting the mass of polymericmaterial onto the thermoformed sheet. The activatable material may beprovided by extrusion or injection molding onto the fiber reinforcedthermoplastic sheet and the mass of polymeric material. The activatablematerial may be an adhesive and/or foamable material. The mass ofpolymeric material may be a short fiber filled polyamide. Theactivatable material may be a heat activated foamable thermosettingresin. The activatable material may contain a heat activated curingagent.

The teachings herein also envision a component comprising a formedcontinuous fiber (e.g. a fibrous insert) reinforced thermoplastic sheetbonded to an additional strengthening material (e.g., a mass ofpolymeric material) and further containing a heat activated material(e.g., an activatable material). The heat activated material may be afoamable and/or adhesive material. The additional strengthening materialmay provide reinforcing ribs extending from one or both sides of theformed continuous fiber reinforced thermoplastic sheet. The additionalstrengthening material may comprise short fiber filled polyamide. Theheat activated material may be provided on selected surfaces of thecontinuous fiber reinforced thermoplastic sheet and/or the additionalstrengthening material. The activatable material may be a heat activatedthermosetting resin. The heat activated thermosetting resin may be anepoxy resin.

The teachings herein further provide for a process for the manufactureof a component comprising thermoforming a continuous fiber reinforcedthermoplastic sheet, providing an additional strengthening material tothe thermoformed sheet and further providing a heat activatable materialto the surface of the thermoformed thermoplastic sheet and/or theadditional strengthening material. The additional strengthening materialmay be provided by placing the thermoformed sheet in a mold andinjecting the additional strengthening material onto the thermoformedsheet. The activatable material may be provided by extrusion orinjection molding onto the bicomponent material of the thermoformedsheet and the additional strengthening material. The activatablematerial may be an adhesive and/or foamable material. The additionalstrengthening material may be short fiber filled polyamide. Theactivatable material may be a heat activated foamable thermosettingresin. The foamable thermosetting resin may contain a heat activatedcuring agent.

The present teachings also envision a process for providingreinforcement in cavities comprising placing a component according tothe present teachings in a cavity and heating to activate theactivatable material. The cavity may be a cavity in a vehicle body shelland the heating is effected at a temperature of from 140° C. to 220° C.

The teachings herein further provide for the use of the component of anyof the teachings herein in the production of components for theautomotive or aerospace industries.

Parts made in accordance with the present teachings have application intransportation vehicles (e.g., automotive vehicles). For example, asnoted above, such parts may employ an activatable material that, uponactivation (e.g., by a suitable energy source, such as heat from a paintbake oven), will expand and cure to form a foamed material. Theresulting activated material may have application for impartingstructural rigidity or reinforcement (i.e., it may be what is regardedas a structural foam; examples of structural foam include, withoutlimitation, those available from L & L Products, Inc. under the namesL5204, L5207, L5214, L5234, L5235, L5236, L5239, L5244, L5505, L5510,L5520, L5540, L5800, L5810 and L8514). The resulting activated materialmay have application for sealing and/or noise abatement. The resultingactivated material may be expanded to at least about 50%, 100%, 200%,400%, 600%, or even 1000% of its original volume. The resultingactivated material may be expanded from its original volume, but in anamount that is below about 2500%, 2000% or even below about 1500% of itsoriginal volume.

Advantageously, the teachings herein provide an improved approach to thestructure and/or formation of carriers in that multiple dissimilarmaterials may be employed and will exhibit a unitary structure that isgenerally continuous throughout the carrier. Exposed surfaces of thecarriers of the present teachings may be generally smooth and/orcontinuous. For instance, contemplated within the teachings herein arecarriers that have a polymeric portion, a localized reinforcementportion and an interface portion between the polymeric portion and thelocalized reinforcement portion wherein the polymeric portion, theinterface portion and the localized reinforcement portion are agenerally smooth and/or continuous structure. The interface portion mayinclude an interpenetrating network defined by the polymeric materialsof the polymeric portion and the localized reinforcement portion. Theinterface portion may include chemical bonds between the polymer of thepolymeric portion and the polymer of the localized reinforcementportion. In this manner, the resulting carrier may thus exhibit no knitlines visible to the naked eye. The resulting carrier may also exhibitno voids or discontinuities visible to the naked eye across theinterface portion.

The teachings herein also make it possible to design a range of carriersthat include localized reinforcement regions that can be readilymanufactured.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side sectional view of a portion of one illustrative part inaccordance with the present teachings.

FIG. 2 is a side sectional view of a portion of another illustrativepart in accordance with the present teachings.

FIG. 3 is a side sectional view of a portion of yet another illustrativepart in accordance with the present teachings.

FIG. 4a is a top perspective view of one illustrative carrier inaccordance with the present teachings.

FIG. 4b is a bottom perspective view of the carrier of FIG. 4 a.

FIG. 5 is an exploded perspective view of one illustrative lay-up of afibrous insert of the present teachings.

FIG. 6a is a perspective view of an illustrative fibrous insert inaccordance with the present teachings.

FIG. 6b is a perspective view of an illustrative part incorporating thefibrous insert of FIG. 6 a.

FIG. 7a is a perspective view of another illustrative fibrous insert inaccordance with the present teachings.

FIG. 7b is a perspective view of an illustrative part incorporating thefibrous insert of FIG. 6 a.

FIG. 8 is a schematic illustrating the formation of an illustrative partin accordance with the present teachings.

FIG. 9 is a schematic illustration of a molding process.

FIGS. 10 and 11 compare the properties of the product of the inventionwith glass fiber reinforced polyamide and steel.

DETAILED DESCRIPTION

Continuous fiber reinforced thermoplastic materials comprise continuousfibers which may be glass fiber, carbon fiber or aramid fiber embeddedin a thermoplastic matrix. The fibers may be tows of individual fibersor they may be woven or non-woven materials. The materials are typicallyobtained as sheets of material for subsequent forming and the continuousfibers preferably lie along the Y axis of the sheet and are continuousalong the length of the sheet. The continuous fiber reinforcedthermoplastic materials may be used on their own or alternatively theymay be used in composites together with other materials. They may bebonded to automotive or aerospace structures by means of structuraladhesives which can be heat activated and can also be foamable. Forexample, the material may be laminated to other materials such as shortfiber filled thermoplastic materials and/or they may be laminated tofoamable materials which may be thermoplastic or thermosettingmaterials. The continuous fiber reinforced materials are typically plainsheets of fully impregnated and consolidated materials substantiallyfree of air and voids. The materials are typically obtained as sheets ofmaterial for subsequent forming and the continuous fibers preferably liealong the Y axis of the sheet and are continuous along the length of thesheet.

Where they are sheets they are typically from between 0.2 to 6.0 mmthick and can be of any desired width, we have found that useful widthsare from 600 to 1200 mm. The fiber may be glass fiber, carbon fiber oraramid fiber and we prefer that the fiber content of the sheet is from45 to 75 by volume %. We have found that sheets with these propertiescan be readily thermoformed to produce either the component for use inthe vehicle or thermoformed together with other sheet materials to forma component for use in a vehicle. The material may also form a carrierfor subsequently bonding to a further material for use as a component.

As indicated the continuous fibers may be glass fiber, carbon fiber oraramid fiber. The choice of the thermoplastic material in which thecontinuous fibers are embedded will depend upon the ultimate use anddesired properties of the component. Preferred thermoplastics from whichthe thermoplastic may be selected are polyolefins such as the variousforms of polyethylene, polypropylene, olefin copolymers, polymericrubbers. Other thermoplastics that can be used include polyamides,polyimides, thermoplastic polyesters and polyketones. The continuousfiber reinforced materials may be readily shaped by thermoforming in asuitable mold. For example, a sheet may be placed in a mold and heatedto the softening temperature of the thermoplastic material and pressureapplied to shape the material in the mold to the desired shape which isretained once the material cools to below the softening point. Such atechnique has been found to be useful in producing components of complexshape. The process may also be used to produce laminates of thecontinuous fiber reinforced thermoplastic with other materials either byheat bonding the materials at the temperatures employed forthermoforming the sheet of continuous fiber reinforced thermoplastic orby employing a heat activated adhesive that is activated at thetemperature used for the thermoforming.

The shaped continuous fiber reinforced product may be laminated to othermaterials such as additional reinforcing materials and/or foamablematerials over all or part of its surface to provide foamable materialsover all or part of its surface to provide foamable components for thestructural reinforcement of automobiles useful in the manner describedabove. The preferred materials for providing structural reinforcementare heat curable and may be heat foamable materials which arethermoplastic and which can be processed at temperatures below that atwhich cure occurs. Examples of such products are those available from L& L Products under the names L5204, L5207, L5214, L5234, L5235, L5236,L5239, L5244, L5505, L5510, L5520. L5540, L5800, L5810 and L8514.

In a particular embodiment the continuous fiber reinforced thermoplasticmaterial may be thermoformed to a desired shape in a press or mold. Thethermoformed material may then be located in a mold which provides spacefor additional material to be provided by overmolding onto thethermoformed material. Additional material may be introduced into themold and bonded to the thermoformed material. The additional materialmay be thermoplastic and the mold may be such that the additionalmaterial is shaped to provide, for example, reinforcing ribs projectingfrom the thermoformed material. The ribs or other shapes can be providedon one or both sides of the thermoformed material. The ribs or othershapes can be provided on one or both sides of the thermoformedcontinuous fiber reinforced thermoplastic material. The materials arepreferably provided by injection molding and the preferred additionalmaterial is glass filled nylon.

In another aspect of the present teachings there is contemplated astructural reinforcement for an article. The structural reinforcementincludes a carrier that includes a mass of polymeric material having anouter surface and including a first polymeric material (e.g., a firstthermoplastic material). The carrier also includes at least oneconsolidated fibrous insert (which may have a predetermined ordering offibers within the insert and/or may have a three dimensional shapedconfiguration) having an outer surface. The at least one consolidatedfibrous insert includes at least one elongated fiber arrangement (e.g.,having a mass of continuous fibers, which may be in an orderedarrangement, such as by being generally axially aligned relative to eachother) distributed in a cohesive mass of a second polymeric material(e.g., a second thermoplastic material). The fibrous insert adjoins themass of the first polymeric material in a predetermined location forcarrying a predetermined load that is subjected upon the predeterminedlocation. The fibrous insert and the mass of first polymeric materialinclude compatible materials, structures or both, for allowing thefibrous insert to be at least partially joined to the mass of thepolymeric material. The structural reinforcement also includes a mass ofactivatable material selectively applied over at least a portion of oneor both of the outer surface of the mass of the polymeric material orthe fibrous insert (e.g., on exterior peripheral surface of the carrier,within a cavity of the carrier, or both). The mass of activatablematerial is capable of activation for expansion by an external stimulus(e.g., heat, moisture, radiation or otherwise) and is capable of curingto form an adhesive bond to at least one surface of the article.Desirably the outer surface of the fibrous insert may be at leastpartially co-extensive and continuous with the outer surface of the massof polymeric material.

As indicated, the first and second polymeric materials may bethermoplastic. For example, the first and second materials may be apolyamide, a polyolefin (e.g., polyethylene, polypropylene, orotherwise), a polycarbonate, a polyester (e.g., polyethyleneterephthalate), a thermoplastic polyurethane, or any combinationthereof. It is preferred to employ a polyamide (e.g., polyamide 6,polyamide 6,6, polyamide 9, polyamide 10, polyamide 12 or the like). Thefirst and the second materials are generally compatible with each otherin that they are capable of forming a mechanical or other physicalinterconnection (e.g., a microscopic interconnection) between them, theyare capable of forming a chemical bond between them, or both. Forexample, the first and second materials may be such that they fusetogether (e.g., in the absence of any adhesive) when heated above theirmelting point and/or their softening point. The first polymericmaterial, the second polymeric material or both may be filled withchopped fibers (e.g., chopped glass fibers), which may be present inamount of about 25 to about 40 (e.g., about 30 to about 35) weightpercent chopped fibers. The average length of such fibers may be belowabout 20 mm, below about 10 mm or even below about 5 mm. They may berandomly oriented. The first and second materials may be free of anymetallic materials.

The fibrous insert may include one or more layers (e.g., they may have2, 3, 4, 6 or more layers) that are consolidated in the sense that theyinclude a plurality of individual fibers that are distributed in acohesive mass of the second polymeric material. The individual fibersmay be distributed in a predetermined ordered arrangement within amatrix of the second polymeric material. Preferably at least a portionof the fibers are ordered in their arrangement (e.g., in a generallyordered relationship relative to each other, such as generally parallelor unidirectional or otherwise generally axially aligned), and thus arenot randomly distributed in the second polymeric material. Multiplelayers may be consolidated together so that a cohesive mass, includingthe multiple layers, is formed. The multiple layers may be consolidatedso as to form a predetermined shape in the form of a three-dimensionalshaped insert. For instance, the fibrous insert may employ a pluralityof layers that include a plurality of elongated fibers (e.g., having alength of at least 1 cm, 3 cm or even 5 cm or longer) that are orientedgenerally parallel or generally unidirectionally to each other and aredistributed in a generally continuous polymeric matrix (e.g., in acontinuous matrix of the second polymeric material). The fibers may bemineral fibers (e.g., glass fibers, such as E-glass fibers, S-glass,B-glass or otherwise), polymeric fibers (e.g., an aramid fiber, acellulose fiber, or otherwise), carbon fibers, metal fibers, naturalfibers (e.g., derived from an agricultural source), or otherwise.Desirably the fibers are glass fibers. The plurality of elongated fibersmay be oriented generally parallel to each other. They may be braided.They may be twisted. Collections of fibers may be woven and/or nonwoven.The fibers may have an average diameter of about 1 to about 50 microns(e.g., about 5 to about 25 microns). The fibers may have a suitablesizing coating thereon. The fibers may be present in each layer, or inthe fibrous insert generally, in an amount of at least about 20%, 30%,40% or even 50% by weight. The fibers may be present in each layer, orin the fibrous insert generally, in an amount below about 90%, 80%, oreven about 70%, by weight. By way of example, the fibers may be presentin each layer, or in the fibrous insert, in an amount of about 50% toabout 70% by weight. Fiber contents by weight may be determined inaccordance with ASTM D2584-11. Tapes and/or sheets for the layers of thefibrous insert may be made by extrusion, pultrusion or otherwise. Inthis manner, it may be possible to achieve ordering of the fibers in thetapes and/or sheets. The method herein may include a step ofimpregnating a fibrous mass with the material of the polymeric matrixand passing the resulting impregnated material through a die (e.g., aheated die) so that the fibrous mass is coated with a generallycontinuous mass of the material of the polymeric matrix. In this manner,it is also possible to achieve desired ordering of fibers relative toeach other.

Each layer of the fibrous insert may be in the form of a sheet, a tapeor otherwise. Fibers in the sheet and/or tape preferably may have anordered relationship relative to each other. For example, the fibers maybe generally parallel with each other and/or oriented unidirectionally.When consolidating multiple layers of sheet, tape or other form of layerto form a multi-ply fibrous insert, it is preferred that at least onelayer of the fibrous insert exhibits an ordered relationship, as opposedto a random relationship, such as is found in fiber mats, whichtypically employ chopped fibers that are randomly laid across eachother.

It is possible that the layers of the fibrous insert are provided asbeing wound on a reel. Each layer may have a thickness of at least about0.1 mm or at least about 0.2 mm. Each layer may have a thickness belowabout 0.5 mm or below about 0.4 mm. For instance, each layer may beabout 0.2 to about 0.3 mm in thickness. Some or all of the individuallayers may be anisotropic in its mechanical properties. For example, itmay exhibit a relatively high flexural modulus and/or strength in alongitudinal direction, but a lower flexural modulus and/or strength ina transverse direction, or vice versa.

The fibrous insert may include a plurality of woven strips. For example,it may include a plurality of strips that are cross woven, each striphaving a width of at least about 1 mm, at least about 2 mm, or even atleast about 3 mm. It may include a plurality of strips that are crosswoven, each having a width below about 10 mm, below about 8 mm, or evenbelow about 6 mm. The woven strips may be held together by a polymericmatrix material, e.g., a continuous matrix of the polymeric material ofthe insert. Thus, the strips are fixed in a predetermined positionrelative to each other by virtue of the polymeric material. It ispreferred that at least some of the strips may each include a pluralityof elongated fibers arranged in an ordered relationship relative to eachother, desirably within a continuous matrix of polymeric material.However, it is possible that one or more strips may include fibershaving a random orientation relationship relative to each other, such asis derived from typical fiber mats. Strips for forming weaves may bemade by slitting a tape, sheet or other form to an appropriate width toform strips. Alternatively, it may be possible that the strips arepultruded, extruded or otherwise formed (as described herein) in thedesired width.

The material defining the fibrous insert may exhibit a flexural strengthper ASTM D790-10 of at least about 450 MPa (e.g., it may range fromabout 500 to about 1100 MPa). The material of the fibrous insert mayexhibit a flexural modulus per ASTM D790-10 of at least about 5 GPa, 10GPa, 20 GPa, or even at least about 25 GPa (e.g., it may range fromabout 30 to about 35 GPa).

The fibrous insert may employ fully densified polymer for the polymericmatrix. The fibrous insert may have a void content that is below about10% by volume of the insert, and more preferably below about 5% or evenbelow about 2% or 1% as measured by ASTM D2734-09. The fibrous insertmay have a density that is below about 40% the density of steel, belowabout 33% the density of steel, or even below about 25% the density ofplain carbon steel.

The fibrous insert may be made to include a plurality of adjoininglayers. The adjoining layers may have fiber orientations that are thesame or different relative to each other. The fibrous insert may includea woven layer adjoining a non-woven layer. The fibrous insert mayinclude a woven layer adjoining another woven layer. The weave patternof woven layers within the fibrous insert may be the same or may varybetween such woven layers. The width of strips may vary betweenadjoining layers. The thickness of adjoining layers may be the same ordifferent.

Examples of weave patterns include plain weaves, twill weaves, orotherwise. Overlapping strips may be woven generally orthogonal to oneanother or at some other angle. The weave may include a plurality ofwarp and weft strips. The ratio of warp to weft strips may range fromabout 30:70 to about 70:30. For example it may be about 50:50. It ispossible that strips of the warp and weft members may have generally thesame width. The warp strip and weft strip widths may vary relative toeach other by 10%, 20%, 30% or more. The warp strip and weft stripwidths may vary relative to each other by less than about 70%, 60%, 50%or less.

Each adjoining layer of tape and/or sheet in the fibrous inserts hereinmay be oriented so that it has fibers (i.e., the fibers that areembedded in the polymeric matrix of the tape and/or sheet) aligned in adifferent predetermined direction relative to fibers of an adjoininglayer. Fibers in one layer may be generally at an angle relative tofibers in an adjoining layer (e.g., the axis of fiber orientation asbetween layers may differ from about 10 to about 90°, such as in theform of an X-ply). For example, one multiple layer structure may includeone layer that may have fibers oriented in a first direction of a firstplane, and an adjoining layer oriented with its fibers generally in asecond plane parallel to the first plane, but at an approximately 90degree angle.

Desirably each of the adjoining layers are joined together as a cohesivemass. For instance, each of the layers may be bonded together by thepolymeric material of the respective layers to form a series ofcontinuous layers. The layers may be bonded together in the absence ofany adhesive.

The fibrous insert may have one or more structural features incorporatedtherein or attached thereto. For example, one or more fasteners may beemployed (e.g., one or more threaded fasteners). One or more lugs may beformed or integrated into the fibrous insert (e.g., for providing a gapfor the passage of a coating fluid). One or more rivets (e.g., aself-piercing rivet, a blind rivet or both) may be integrated into theinsert. One or more metal blanks may be integrated into the insert,which may be adapted to provide a location on a resulting part for spotwelding. One or more studs may be integrated into the insert (e.g.,having a base that may have apertures defined therein, which is locatedwithin or on a surface of the fibrous insert and which has a post (e.g.,a threaded post) that extends outward from the base).

As indicated the fibrous inserts may have a predetermined shape. Theshape may be the result of one or more calculations performed during astep of computer simulation of a crash, a certain stress state orotherwise, and may be selected so as to provide additional localizedreinforcement in a predetermined region of the part that will besubjected to a predicted stress condition that is determined from suchcalculations. The fibrous inserts herein may include one or anycombination of a generally sinusoidal geometry over some or all of itslength, a pair of spaced apart walls that are joined together by a crosswall, one or more ledges and/or steps, a concave surface portion, aconvex surface region, or one or more apertures. As indicated, thefibrous inserts herein may have a three dimensional configuration, incontrast with a generally planar configuration.

The characteristics of the fibrous insert can vary from application toapplication. One benefit of the present teachings is the layers of thefibrous insert can be selected to meet the needs of a particularapplication (e.g., in response to modeling by computer simulation (suchas computer crash or stress state simulation)). The insert can beindividually built up to include a plurality of layers based upon theperformance demanded by the application. Moreover, another benefit ofthe teachings herein is that localized reinforcement can be achieved bylocating the inserts in particular locations that are indicated asrequiring additional local reinforcement (e.g., in response to modelingby computer simulation (such as computer crash or stress statesimulation)). The teachings herein thus afford the skilled person with asurprisingly expanded ability to selectively tune performance ofstructural reinforcements. The teachings also contemplate the use ofmodeling by computer simulation to determine the location at which acarrier is expected to carry a predetermined load in a crash or under acertain stress state. Based upon the results of such modeling, thelocation at which a fibrous insert should be located can be determined.Also, based upon the results of such modeling, the orientation of fibersand/or the selection of respective adjoining layers of tape or sheet ina fibrous insert can be ascertained. Parts can thereafter be made thatare based upon the designs resulting from such modeling. Methodsemploying such steps are thus within the present teachings as well.

The carriers of the structural reinforcements may be such that the outersurface of the fibrous insert is generally co-extensive with the outersurface of the mass of polymeric material. This may be over some or allof the perimeter of the fibrous insert. It is also envisioned that thefibrous insert may have opposing surfaces that are each exposed and thusvisible in the resulting part. For instance, the fibrous insert may havean exposed outer surface and an exposed inner surface. Thus, the fibrousinsert may adjoin the mass of polymeric material only along one or moreside edges of the fibrous insert. The resulting visible surfaces of thecarrier may be substantially free of knit lines or other imperfectionsthat could provide a source of localized weakening of the carrier.

As appreciated from the above, the carrier may have (i) a polymericportion defined by the mass of first polymeric material, (ii) alocalized reinforcement portion defined by the at least one fibrousinsert, and (iii) an interface portion between the polymeric portion andthe localized reinforcement portion wherein the polymeric portion, theinterface portion and the localized reinforcement portion are agenerally continuous structure. The interface portion may include (i) aninterpenetrating network defined by the first and second polymericmaterials, (ii) chemical bonds between the first and second polymericmaterials, or both (i) and (ii).

One or more sides of the activatable material may be tacky. Though it isalso possible that one or more sides will be generally tack free to thetouch at room temperature. One or more mechanical fasteners may beemployed by attaching to or being formed integral with the activatablematerial, the carrier, or both.

Suitable materials that may be employed for the activatable materialinclude expandable materials and materials that do not expand. However,it is contemplated that the activatable material can be activated toform a foam. For instance, the material may be activated to form astructural foam (e.g., the material may include an epoxy ingredient).The material may be activated to form an acoustic foam. The material maybe activated to flow for purposes of sealing a region within a cavity.The material may include a combination of a material that is activatableto expand and a material that is not activatable to expand.

The structural reinforcement of the present teachings may be employedfor structurally reinforcing an article, such as by locating thestructural reinforcement within a cavity of the article and activatingthe activatable material so that it expands and bonds to a surface ofthe article. The structural reinforcement may also be employed to sealand/or baffle the cavity. In a preferred application, the structuralreinforcement is employed to reinforce a transportation vehicle, such asan automotive vehicle.

By way of example, the structural reinforcement may be positioned withina cavity of a transportation vehicle (e.g., an automotive vehicle) priorto coating the vehicle. The activatable material may be activated whensubjected to heat during paint shop baking operations. In applicationswhere the activatable material is a heat activated, thermally expandingmaterial, an important consideration involved with the selection andformulation of the material comprising the activatable material is thetemperature at which a material reaction or expansion, and possiblycuring, will take place. For instance, in most applications, it isundesirable for the material to be reactive at room temperature orotherwise at the ambient temperature in a production line environment.More typically, the activatable material becomes reactive at higherprocessing temperatures, such as those encountered in an automobileassembly plant, when the material is processed along with the automobilecomponents at elevated temperatures or at higher applied energy levels,e.g., during paint or e-coat curing or baking steps. While temperaturesencountered in an automobile assembly operation may be in the range ofabout 140° C. to about 220° C., (e.g., about 148.89° C. to about 204.44°C. (about 300° F. to 400° F.)), body and paint shop applications arecommonly about 93.33° C. (about 200° F.) or slightly higher. Followingactivation of the activatable material, the material will typicallycure. Thus, it may be possible that the activatable material may beheated, it may then expand, and may thereafter cure to form a resultingfoamed material.

As indicated, the teachings herein also relate to a method for making acarrier for an activatable material (e.g., for structural reinforcementfor an article). The method may include a step of inserting at least onefibrous insert (which may be consolidated at the time of the step ofinserting) having an outer surface and including at least one elongatedfiber arrangement into a cavity of a tool. A mass of polymeric materialmay be molded in contact with the fibrous insert so that a resultingmolded mass of polymeric material integrally adjoins the fibrous insert(which is consolidated in its final state) and the outer surface of thefibrous insert is at least partially co-extensive and continuous withthe outer surface of the resulting molded mass of polymeric material. Amass of activatable material may be applied (e.g., overmolded,mechanically attached or otherwise) selectively over at least a portionof one or both of the outer surface of the resulting mass of thepolymeric material or the fibrous insert. Consistent with the teachingsabove, the mass of activatable material may be capable of activation forexpansion by an external stimulus (e.g., to at least partially, if notcompletely, fill a gap or a cavity) and may be capable of curing to forman adhesive bond to at least one surface of the article to which it isattached.

The method may include a step of at least partially shaping the fibrousinsert after it is placed in the cavity of the tool. For example, thetool may be preheated to a temperature above the softening temperatureand/or the melting temperature of a polymer of the at least one fibrousinsert prior to placing the fibrous insert in the cavity of the tool.The method may include a step of at least partially shaping the fibrousinsert after it is placed in the cavity of the tool and while moldingthe mass of polymeric material. For instance, heat and/or pressure thatresults from introducing the mass of polymeric material into the cavity(e.g., by injection molding), may at least partially cause the fibrousinsert to assume a shape dictated by one or more of the walls definingthe cavity. Thus it is possible that the fibrous insert is not preformedprior to placement in the cavity, and it assumes its final shape onlywhile in the cavity. Of course, it is also possible that the fibrousinsert is preformed prior to placement in the cavity.

The fibrous insert, prior to the inserting step, may be provided in theform of one or more layers of a tape and/or sheet, in which the fibersmay be fixed in position relative to each other (e.g., as a result ofconsolidation, by which a cohesive mass of the fibers distributed in acontinuous polymeric matrix is formed). The method may thus include astep of fabricating the fibrous insert to include a plurality of layersof tape and/or sheet. For example, the method includes a step ofconsolidating a plurality of layers of tape and/or sheet while theplurality of layers is subjected to heat and optionally an elevatedpressure. For instance, a temperature may be employed that is above themelting and/or softening point of the polymer of the tape and/or sheetto cause two or more adjoining layers to fuse and remain joined togetherupon cooling. A pressure of about 0.1 to about 1 MPa may be applied(e.g., about 0.2 to about 0.6 MPa). The temperature and pressure may beemployed for a desired amount of time to achieve essentially completedensification. It will be appreciated that the teachings afford for theformation of various consolidated insert structures.

The fibrous insert may be thermoformed to form a predetermined shape.The fibrous insert may be thermoformed during a step of consolidating. Aresulting thermoformed fibrous insert may thereafter be placed in a toolcavity and molten thermoplastic polymeric material may be introduced incontact with it.

The step of molding may include a step of introducing molten polymericmaterial into the tool cavity by way of a gate that is positioned ingenerally opposing relationship with the at least one fibrous insert. Inthis manner, upon introduction into the cavity, the molten polymercontacts the fibrous insert before it contacts a wall defining thecavity.

Carriers made in accordance with the present teachings may have a wallhaving a first surface and a generally opposing second surface. The wallmay have a thickness ranging from about 0.2 to about 6 mm (e.g., about1.5 to about 4 mm). At select regions within a carrier, it is possiblethat at least about 20%, 40%, 60%, 80% or even 100% of the wallthickness is defined by the fibrous insert. The fibrous insert may havea contoured outer surface portion that is visibly exposed on thecarrier. The fibrous insert may have a generally flat outer surfaceportion that is visibly exposed on the carrier. The first surface andthe second surface may be generally parallel to each other.

The fibrous insert may occupy at least about 10%, 20%, 30% or even 40%by weight of the overall carrier. The fibrous insert may be less thanabout 90%, 80%, or even 70% by weight of the overall carrier.

Thus it is possible that at least a portion of the first surface and thesecond surface are each visibly exposed and will be composed of thefibrous insert. The carriers may have one or more additional structuralreinforcements or other structural features, such as one or more ribs,bosses or otherwise. These features may be free of or they may include afibrous insert in accordance with the present teachings.

Parts herein may be employed for any of a number of purposes. Forexample, they may be employed to structurally reinforce a transportationvehicle such as an automotive vehicle. In this regard, a part may beplaced in a cavity of a vehicle body structure, such as a vehicle frame.After applying an e-coat layer to the vehicle body (e.g., within thecavity), the part may be subjected to heat from a bake oven, whichcauses the activatable material to activate (e.g., expand and fill thecavity), and become bonded to the vehicle body.

FIGS. 1-5 illustrate examples in accordance with the present teachings.With reference to FIG. 1, there is seen a carrier 10 that has one ormore masses 12 of a first polymeric material. A fibrous insert 14 isshown joined to the one or more masses along an edge of the insert. Aninterface portion 16 is depicted (in exaggerated form for purposes ofillustration; for simplicity such interface is omitted from theremaining drawings, though it should be appreciated that it may stillexist in such embodiments). The carrier has an upper surface 18 and alower surface 20. The fibrous insert 14 spans from the upper surface tothe lower surface so that the fibrous insert is exposed visibly top andbottom. FIG. 1 omits any activatable material. However, activatablematerial can be located over either or both of the mass 12 or thefibrous insert 14.

FIG. 2 depicts a carrier 110 having a mass of polymeric material 112 anda fibrous insert 114, in which only the upper surface of the fibrousinsert is exposed. A lower surface and side edges adjoin the mass ofpolymeric material. The interface region is omitted in this depiction,though it may be present. In this drawing, an expandable material 126 islocated over both the mass of the polymeric material and the fibrousinsert. However, it can be located over one or the other as well.

FIG. 3 illustrates an example of a carrier 210 having a fibrousreinforcement portion 214 with an upper surface 218, from which a rib222 projects, which is made of a mass of polymeric material (e.g., thesame type of material as is otherwise present in the carrier to whichthe insert adjoins). The rib includes an outwardly projecting portionhaving a width w₁, and an enlarged neck region that has a width (at itslargest dimension) w₂ that is larger than the width w₁, such as by anamount of at least about 10%, 20% or 30%. The width w₂ may be largerthan the width w₁, such as by an amount of no greater than about 100%,80% or 60%. A similar rib structure can be employed in the embodiment ofFIG. 2.

FIGS. 4a and 4b illustrate two views of an illustrative carrier 310 thatincludes a mass of polymeric material 312 and a pair of fibrous inserts314. In this instance the fibrous inserts have upper and lower surfacesthat are exposed. Though it is possible to employ a structure like inFIG. 2, in which only an upper surface is exposed. A plurality of ribs322 are employed (ribs are shown in transverse disposition relative to alongitudinal axis (however for all of the embodiments herein, ribs mayrun longitudinally, transverse, diagonally, or any combination thereof;ribs may also be arcuate)). An activatable material 326 is shown. Thoughshown in a groove, it may rest on an outer surface or otherwise becarried on the carrier for all of the embodiments herein.

FIG. 5 illustrates an example of how fibrous inserts 14, 114, 214 or 314can have multiple layers with two or more adjoining layers havingdifferent fiber orientations. Though shown as unidirectionally orientedin this example, strips of impregnated fibers may also be provided as awoven layer. Other orientations than those disclosed in FIG. 5 arepossible. For example three layers of uniaxially oriented fibers may beoriented at 0/90/0 degrees relative to each other, or five layers may beoriented at 0/45/90/45/0 degrees relative to each other. Otherorientations are also possible.

FIGS. 6a and 6b illustrate an example of one part in accordance with thepresent teachings. The part includes a carrier 610 that is shown as amolded part. It includes a fibrous insert 614. The carrier includes aplurality of ribs 622. Activatable material 626 is applied over aportion of the carrier, and is shown as partially covering the insert614. The insert 614, which is overmolded for defining the carrier 610,includes an arcuate surface, and specifically a concave surface portion640. In the embodiment shown, it is located toward an end of the insert614. The insert 614 also includes a through-hole aperture 642. Theinsert includes a pair of opposing walls 644 (which may be generallyparallel or otherwise oriented) and a cross wall 646. The insert spans acentral portion of the carrier.

FIGS. 7a and 7b illustrate an example of another part in accordance withthe present teachings. The part includes a carrier 710 that is shown asa molded part. It includes a fibrous insert 714. The carrier includes aplurality of ribs 722. Activatable material 726 is applied over aportion of the carrier, and is shown as partially covering the insert714. The insert 714, which is overmolded for defining the carrier 710,includes an arcuate surface portion 740. In the embodiment shown, it islocated toward an end of the insert 714. The insert 714 also includes athrough-hole aperture 742. The insert includes a pair of opposing walls744 (which may be generally parallel or otherwise oriented) and a crosswall 746. At least one step 748 is defined in the insert.

FIG. 8 illustrates schematically how a carrier may be made in accordancewith the present teachings. A reel of fibrous material 850 may supplythe material to define an insert 814, shown as being sinusoidal. Theinsert may be overmolded to define overmolded portions 852 (e.g.,including a plurality of ribs) of a resulting carrier 810. The resultingcarrier, thus includes the insert 814 and the overmolded portions 852.

FIGS. 9A-9F are a schematic illustration of a molding process in whichdrawing 9A shows a sheet of the fiber reinforced carrier 3 is heated inthe heater 2 shown in drawing 9B and is then placed in a two componentmold 4 and 5 and is shaped by pressing the upper section of the mold 4downwards to press the carrier 3 to conform to the shape of the mold (5)as shown in drawing 9C. The formed carrier is then removed as shown indrawing 9D and placed in an injection mold 6 where it is firstovermolded with a thermoplastic material 7 as shown in drawing 9E. Theinjection mold is such that it can be opened to provide a space forfurther overmolding with an adhesive material 8 as shown in drawing 9F.

FIGS. 10 and 11 compare the properties of the product of the inventionwith glass fiber reinforced polyamide and steel.

It will be appreciated that, even though the embodiments of FIGS. 1through 11 are shown separately, features of one may be combined withfeatures of another and remain within the present teachings. Thedepictions therein thus should be regarded as generalized and applicableto the teachings as a whole herein.

GENERAL COMMENTS

The teachings herein are illustrated in connection with a carrier for astructural reinforcement, in which the carrier is generally elongated(e.g., it may be at least about 25 mm long, at least about 50 mm long oreven at least about 100 mm long). However, the teachings are notintended to be so limiting. The teachings also contemplate their usagefor forming carriers for baffling and/or sealing. The carriers may thushave lengths that are shorter than about 25 mm (e.g. about 15 mm orshorter). The carriers may be longer than they are wide. The carriersmay be wider than they are long.

As can be appreciated from the teachings herein, various benefits and/oradvantages may be realized. For example, parts may be prepared that havea carrier that is made of a material free of a thermosetting plastic.Parts may be prepared that have at least a portion of the activatablematerial located over and in contact with a fibrous insert of thepresent teachings.

As used herein, unless otherwise stated, the teachings envision that anymember of a genus (list) may be excluded from the genus; and/or anymember of a Markush grouping may be excluded from the grouping.

Unless otherwise stated, any numerical values recited herein include allvalues from the lower value to the upper value in increments of one unitprovided that there is a separation of at least 2 units between anylower value and any higher value. As an example, if it is stated thatthe amount of a component, a property, or a value of a process variablesuch as, for example, temperature, pressure, time and the like is, forexample, from 1 to 90, preferably from 20 to 80, more preferably from 30to 70, it is intended that intermediate range values such as (forexample, 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.) are within theteachings of this specification. Likewise, individual intermediatevalues are also within the present teachings. For values which are lessthan one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 asappropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to be considered to beexpressly stated in this application in a similar manner. As can beseen, the teaching of amounts expressed as “parts by weight” herein alsocontemplates the same ranges expressed in terms of percent by weight.Thus, an expression in the of a range in terms of “at least ‘x’ parts byweight of the resulting composition” also contemplates a teaching ofranges of same recited amount of “x” in percent by weight of theresulting composition.”

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes. The term “consisting essentially of to describe a combinationshall include the elements, ingredients, components or steps identified,and such other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations of elements, ingredients, components or stepsherein also contemplates embodiments that consist of, or consistessentially of the elements, ingredients, components or steps.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps.

It is understood that the above description is intended to beillustrative and not restrictive. Many embodiments as well as manyapplications besides the examples provided will be apparent to those ofskill in the art upon reading the above description. The scope of theinvention should, therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent applications and publications, areincorporated by reference for all purposes. The omission in thefollowing claims of any aspect of subject matter that is disclosedherein is not a disclaimer of such subject matter, nor should it beregarded that the inventors did not consider such subject matter to bepart of the disclosed inventive subject matter.

1-55. (canceled)
 56. A device for structural reinforcement, bafflingand/or sealing of an article, comprising: a. a carrier that includes: i.a mass of polymeric material having an outer surface and including afirst polymeric material; and ii. at least one consolidated fibrousinsert having an outer surface and including at least one elongatedfiber arrangement having a plurality of ordered fibers distributed in apredetermined manner in a second polymeric material, the fibrous insertadjoining the mass of the polymeric material in a predetermined locationfor carrying a predetermined load that is subjected upon thepredetermined location; wherein the fibrous insert and the mass ofpolymeric material include compatible materials, structures or both, forallowing the fibrous insert to be at least partially joined to the massof polymeric material; and b. a mass of activatable material selectivelyapplied over at least a portion of one or both of the outer surface ofthe mass of the polymeric material or the at least one fibrous insert,the mass of activatable material being capable of activation forexpansion by an external stimulus and being capable of curing to form anadhesive bond to at least one surface of the article; wherein the outersurface of the fibrous insert is at least partially co-extensive andcontinuous with the outer surface of the mass of polymeric material. 57.The device of claim 1, wherein the mass of polymeric material includes athermoplastic material.
 58. The device of claim 1, wherein the at leastone consolidated fibrous insert includes at least one layer in the formof a tape material that is made generally of the same type of materialas the mass of polymeric material.
 59. The device of claim 1, whereinthe at least one elongated fiber arrangement of the at least oneconsolidated fibrous insert includes a material that is made generallyof the same type of material as the mass of polymeric material.
 60. Thedevice of claim 1, wherein the at least one elongated fiber arrangementof the at least one consolidated fibrous insert includes a material thatis made generally of the same type of material as the mass of polymericmaterial so that the material of the fibrous insert and the mass ofpolymeric material are chemically fused together.
 61. The device ofclaim 1, wherein the at least one elongated fiber arrangement is a wovenfiber arrangement.
 62. The device of claim 1, wherein the at least oneelongated fiber arrangement is a woven fiber arrangement that isimpregnated with a material that is generally the same type of materialas the material of the mass of polymeric material.
 63. The device ofclaim 1, wherein the at least one elongated fiber arrangement is a wovenfiber arrangement made of a material that is generally of the same typeof material as the mass of polymeric material and is impregnated with amaterial that is generally the same type of material as the material ofthe mass of polymeric material.
 64. The device of claim 1, wherein thefibrous insert includes a plurality of layers each including anelongated fiber arrangement, and each layer being anisotropic in itsmechanical properties.
 65. The device of claim 5, wherein the fibrousinsert includes a plurality of fibers including glass fibers, mineralfibers, carbon fibers, polymeric fibers, or any combination thereof. 66.The device of any of claim 1, wherein the mass of activatable materialincludes an epoxy-based material.
 67. The device of claim 6, wherein theouter surface of the fibrous insert is generally co-extensive with theouter surface of the mass of polymeric material.
 68. The device of claim1, wherein a resulting outer surface of the carrier is substantiallyfree of knit lines or other imperfections that could provide a source oflocalized weakening of the carrier.
 69. The device of claim 1, whereinthe at least one consolidated fibrous insert has an exposed outersurface and an exposed inner surface.
 70. The device of claim 1, whereinthe carrier has (i) a polymeric portion defined by the mass of polymericmaterial, (ii) a localized reinforcement portion defined by the at leastone consolidated fibrous insert, and (iii) an interface portion betweenthe polymeric portion and the localized reinforcement portion whereinthe polymeric portion, the interface portion and the localizedreinforcement portion are a generally smooth and/or continuousstructure.
 71. The device of claim 15, wherein the interface portionincludes (i) an interpenetrating network defined by the first and secondpolymeric materials, (ii) chemical bonds between the first and secondpolymeric materials, or both (i) and (ii).
 72. A method for making adevice for structural reinforcement, baffling and/or sealing of anarticle, comprising: c. inserting at least one consolidated fibrousinsert having an outer surface and including at least one elongatedfiber arrangement into a cavity of a tool; d. molding a mass ofpolymeric material in contact with the fibrous insert so that aresulting molded mass of polymeric material integrally adjoins thefibrous insert and the outer surface of the fibrous insert is at leastpartially co-extensive and continuous with the outer surface of aresulting molded mass of polymeric material; and e. applying a mass ofactivatable material selectively over at least a portion of one or bothof the outer surface of the resulting mass of the polymeric material orthe fibrous insert, the mass of activatable material being capable ofactivation for expansion by an external stimulus and being capable ofcuring to form an adhesive bond to at least one surface of the article.73. The method of claim 17, wherein the tool is preheated to atemperature above the softening temperature and/or the meltingtemperature of a polymer of the at least one consolidated fibrous insertprior to placing the fibrous insert in the cavity of the tool and/or thefibrous insert is not preformed prior to placement in the cavity. 74.The method of claim 18, wherein the method includes a step of at leastpartially shaping the at least one consolidated fibrous insert after itis placed in the cavity of the tool and while molding the mass ofpolymeric material.
 75. The method of claim 17, wherein the at least oneconsolidated fibrous insert, prior to the inserting step, is provided inthe form of a tape or sheet.